1

EMPTY CONTAINER ATTACHMENT

GENERAL

This section has the description and repair procedures
for the attachment that is used for handling empty con-
tainers. There is also information on the operator con-
trols for the attachment.

DESCRIPTION (See FIGURE 1.)

The container attachment for handling empty containers
can be used at widths from 6.1 m (20 feet) to 12.2 m (40
feet). The attachment has a center frame, two outer
booms and a floating beam. The center frame is installed
on the carriage and can move from side to side with the
use of a side–shift cylinder. The outer booms extend and
retract from the center frame through the use of hydrau-
lic (extension) cylinders. The extension cylinders on the
attachment are actuated by hydraulic pressure from the
main control valve. Each of the boom sections have sev-
eral wear plates. The wear plates support the boom sec-
tions and reduce friction as they extend and retract. The
floating beam moves within the outer booms for sup-
port. A vertical tube is welded to the end of each outer
boom. An end beam assembly fits into each tube. The

end beams have the mechanism to lock the container to
the attachment. The end beams can move vertically (150
mm/5.9 in) to adjust for uneven surfaces. Header hoses
and an electrical cable connect the hydraulic and electri-
cal circuits between the lift truck and the attachment.

OPERATION (See FIGURE 2.)

The hydraulic functions for the attachment are con-
trolled by the auxiliary control valve. The operator actu-
ates the auxiliary control valve with switches in the op-
erator’s compartment. The oil from the auxiliary control
valve is used to move the auxiliary spool in the main
control valve. Oil from the auxiliary spool flows to the
selector valves on the attachment. See THE MAIN
CONTROL VALVE, 2000 SRM 444, for information
about the hydraulic controls.

Selector Valves
(See FIGURE 1. and FIGURE 2.)

A selector valve opens and closes a hydraulic circuit for
one function. Each valve has one solenoid that operates
one spool. Selector valves are mounted on a common
hydraulic manifold on the attachment.

FIGURE 1. EMPTY CONTAINER ATTACHMENT

5. RIGHT–HAND OUTER BOOM
6. CENTER FRAME
7. LEFT–HAND OUTER BOOM
8. END BEAM

1. LOCKING HEAD
2. SELECTOR VALVE ASSEMBLY
3. CARRIAGE
4. FLEXIBLE CABLE GUIDE

1

2

3

4

5

6

7

8

8

2

FIGURE 2. HYDRAULIC SCHEMATIC

1. EXTENSION

CYLINDER

2. CHECK VALVE
3. SELECTOR VALVE

(EXTENSION CYLINDERS)

4. SELECTOR VALVE

(LOCK PIN CYLINDERS)

5. SELECTOR VALVE

(SIDE–SHIFT CYLINDER)

6. SIDE–SHIFT CYLINDER
7. LOCK PIN CYLINDER

AY

AX

1

2

3

6

4

5

2

2

7

Side–Shift Circuit
(See FIGURE 2. And FIGURE 4.)

The attachment can move from side–to–side on the car-
riage. The side–shift cylinder is connected between the
carriage and the center frame. There are horizontal and
vertical load rollers to guide the movement of the attach-
ment on the carriage.

Extend/Retract Circuit
(See FIGURE 2. And FIGURE 4.)

The attachment can extend from 6.1 m (20 foot) to 12.2
m (40 foot) for different container sizes. Oil from the
main control valve (auxiliary spool) enters the selector
valve and then to the cylinders. Oil goes to the piston end
of each extension cylinder. As the cylinders extend, oil
from the rod end of the cylinders returns to the hydraulic
tank. The shell of each extension cylinder is fastened to

the center frame. The rod end of each extension cylinder
is fastened to an outer boom. As the cylinders extend,
they push on the outer booms.

To retract the attachment, the oil enters the rod end of the
extension cylinders. As the extension cylinders retract,
they pull in the outer booms.

Lock Pin Circuit
(See FIGURE 2., FIGURE 3. And FIGURE 4.)

The end beam assemblies have the components for the
lock pin circuit. Each lock pin circuit uses a lock pin cyl-
inder and three proximity switches– lock pin locked,
lock pin unlocked, and container seated

To pick up a container, the lock pins must be retracted.
When the lock pins are retracted, they turn on proximity
switches. When the proximity switches (unlocked) for
both lock pins are actuated, the amber light on the con-

3

trol panel will turn on. As the attachment is set on a con-
tainer, the vertical guides enter the top openings in the
corner pockets of the container. A spring–loaded button
at each corner is pushed up by the container. In the up
position, the buttons actuate proximity switches
(seated) that energize the lock pin circuit. Both of these
buttons must be depressed before the lock pin switch is
energized.

When the operator actuates the lock pin switch to en-
gage the container, the selector valve lets oil flow to the
piston side of the lock pin cylinders, extending the lock
pins. With the lock pins extended, another set of
switches (locked) are actuated by the lock pins. A green
light on the control console turns on when both of these
switches (locked) are actuated.

When the container is lifted, the buttons extend. The
switches (seated) are turned off, and the circuit to the
lock pin switch is deenergized. The lock pins can not be
retracted while the container is raised. Lowering the
container to the surface or on top of another container
pushes on the buttons so that the buttons are aligned with

the switches (seated) again. The operator can now re-
tract the lock pins and release the container.

FIGURE 3. END BEAM

1. LOCK PIN

CYLINDER

2. SWITCH–

UNLOCKED

3. SWITCH–

LOCKED

1

2

3

4

5

6

7

4. SWITCH–

SEATED

5. GUIDE
6. BUTTON
7. LOCK PIN

FIGURE 4. OPERATOR CONTROLS

1. OVERRIDE SWITCH
2. LOCK PIN SWITCH
3. GREEN LIGHT
4. AMBER LIGHT

5. EXTEND/RETRACT SWITCH
6. SIDE–SHIFT SWITCH

2

4

5

6

1

3

4

FIGURE 5. ARRANGEMENT OF THE ATTACHMENT

FRONT

1. OUTER BOOM (LEFT)
2. FLOATING BEAM
3. CENTER FRAME
4. OUTER BOOM (RIGHT)

1

2

3

4

5

REPAIRS

CARRIAGE

Removal

NOTE: The carriage and attachment are removed to-
gether. See the procedure CONTAINER ATTACH-
MENT, Removal.

Disassembly (See FIGURE 6.)

1. Put the carriage on blocks so that the load rollers are
off the ground.

2. Remove the load rollers, bearing blocks and wear
plates as necessary.

Assembly (See FIGURE 6.)

1. Install the load rollers on the carriage as follows:

a. Lubricate the bearings with multi–purpose

grease.

b. Install the load roller on the shaft. Install the re-

tainer and capscrews. (Do not add shims at this
time.) Tighten the capscrews to 26 N.m (19 lbf
ft).

c. Measure the clearance between the retainer and

the outer bearing. Add shims under the retainer so
that there will be zero clearance. Install the re-
tainer and tighten the capscrews to 66 N.m (48 lbf
ft). Check that the load roller rotates freely.

2. Install the brackets for the bearing blocks and tighten
the capscrews for the brackets to 66 N.m (48 lbf ft).
Install the bearing blocks and shims on the brackets. Lu-
bricate the surface of the bearing block with multi–pur-
pose grease. See CHECKS AND ADJUSTMENTS at
the end of this section.

3. Install the side rollers on the carriage.

FIGURE 6. CARRIAGE

1. PLATE
2. SIDE ROLLER ASSEMBLY
3. WEAR PLATE
4. SHIM
5. CARRIAGE
6. BEARING BLOCK
7. BRACKET

8. BEARING BLOCK
9. SHIM

10. LOAD ROLLER ASSEMBLY

1

2

3

4

5

8

7

6

6

9

10

2

6

Installation

NOTE: The carriage and attachment are installed to-
gether. See the procedure CONTAINER ATTACH-
MENT, Installation.

CONTAINER ATTACHMENT

NOTE: Most repairs for the attachment can be done
while the attachment is installed on the lift truck. If the
attachment must be removed, use the following proce-
dures.

Removal

1. Retract the attachment to the 6.1 m (20 ft) width. Use
the side–shift cylinder to move the attachment to the
center of the carriage. Put the mast in a vertical position.
Lower the carriage onto blocks [approximately 30 cm
(12 in)] so that the lift chains and hoses are loose.

2. Disconnect the lift chains at the carriage. Attach a
rope to the ends of each lift chain to control their move-
ment. Disconnect the two hydraulic lines and the electri-
cal cable at the header hose bracket. Put caps on the open
lines. Remove the clamps as necessary to remove the
harness from the carriage.

WARNING

Make sure that the attachment is stable and will not
fall over. The attachment weighs approximately
5 540 kg (12,000 lb). Make sure the lifting device and
supports can hold the weight. The attachment is
heavy and can be damaged or cause an injury if it
falls.

3. Connect a lifting device to the top bar on the inner
weldment of the mast. Make sure the attachment is sta-
ble, then raise the inner weldment until it disengages
from the carriage. Carefully move the lift truck away
from the attachment.

4. Use the following procedure to remove the carriage
from the attachment:

a. Disconnect all hoses and the electric cable be-

tween the carriage and the center frame.

b. Remove the stop block for the side shift of the

carriage from the center frame.

c. Extend the side shift cylinder as far as possible.

Retract the cylinder 2 cm. (0.75 in.). Disconnect
the cylinder from the carriage.

d. Connect a lifting device to the the carriage. Move

the carriage to the side until the rollers are free.
Remove the retainer bars at the bottom of the car-
riage. Use the lifting device to move the carriage
from the attachment.

Disassembly (See FIGURE 5.)

WARNING

Do not work under a raised carriage. Lower the car-
riage or use a chain to prevent the carriage and inner
mast from lowering. Attach all moving parts of the
mast to the parts that DO NOT move with a chain
and make secure.

1. Extend the attachment to the 40 foot position. Discon-
nect the extension cylinders at the outer booms. Make a
note of the arrangement of washers at the end of the rod.
Retract the extension cylinders, being careful not to
damage the cylinder rods.

2. Disconnect the flexible cable guides at the end beams.
Disconnect the hydraulic lines and electrical cables at
the end beams. Lay the cable guides on the center frame.

3. Move the stops at the outer ends of the center frame to
the open position. The stops are at the back of the attach-
ment.

4. Connect a lifting device with a strap to the left–hand
outer boom. Remove the stop block for the floating
beam from the outer boom. Pull the outer boom from the
center frame, moving the strap as necessary to keep the
boom balanced. Remove the boom and put it on a stand.

5. Make sure the floating beam is inside the right–hand
outer boom as far as possible. Connect a lifting device
with a strap to the right–hand outer boom. Pull the outer
boom from the center frame, moving the strap as neces-
sary to keep the boom balanced. Remove the boom and
put it on a stand.

6. Remove the stop block for the floating beam from the
right–hand outer boom. Pull the floating beam from the
outer boom. Connect a lifting device with a strap to the
floating beam. Pull the floating beam from the outer
boom, moving the strap as necessary to keep the beam
balanced. Remove the beam and put it on a stand.

7

7. Remove the wear plates from the attachment parts.
Make a note of the number and location of shims for the
wear plates.

Cleaning and Inspection

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety precautions.

Clean all the parts of the boom sections with solvent. In-
spect all the welds for cracks. Inspect the wear plates for
damage, deep grooves or cracks. Check the wear sur-
faces of the boom sections. Install new wear plates as
needed. New wear plates must be installed when their
height is at the same level as their keeper plates. Inspect
the rollers on the carriage for wear or damage. These
rollers can only be installed when the carriage is re-
moved.

Assembly (See FIGURE 5.)

1. Install the wear plates and shims on the attachment
parts. Install the keeper plates and capscrews to keep the
wear plates in position. Lubricate the wear plates in the
center frame, floating beam and the outer booms with
multi–purpose grease.

2. Connect a lifting device to the floating beam. Engage
the floating beam with the right–hand outer boom.
Install the stop block for the floating beam on the outer
boom.

3. Connect a lifting device to the right–hand outer boom.
Install the outer boom in the center frame.

4. Connect a lifting device to the left–hand outer boom.
Install the left–hand outer boom into the center frame.
Install the stop block for the floating beam on the outer
boom.

5. Move the stops at the outer ends of the center frame to
the closed position.

6. Connect the flexible cable guide at the end beam.
Connect the wire harness and hydraulic lines to the fit-
tings on the end beam.

7. Connect the extension cylinders to the outer booms.
Make sure to install the washers in the arrangement
noted during disassembly.

Installation

WARNING

Make sure that the attachment is stable and will not
fall over. The attachment weighs approximately
5540 kg (12,000 lb). Make sure the lifting device and
supports can hold the weight. The attachment is
heavy and can be damaged or cause an injury if it
falls.

1. If the carriage was removed, install it as follows:

a. Connect the lifting device to the carriage. Move

the carriage to the side until it engages with the
attachment.

b. Install the retainer bars on the carriage.

c. Connect the side–shift cylinder to the attachment

and the carriage.

d. Retract the side–shift cylinder. Install the stop

block for the side–shift on the center frame.

e. Connect the hoses and electric cable to the center

frame.

2. Connect the lifting device to the top bar on the inner
weldment of the mast. Move the lift truck to the attach-
ment and lower the inner mast to engage the carriage.
Connect the chain anchors to the carriage. Adjust the lift
chains as described in CHECKS AND ADJUST-
MENTS.

3. Connect the hydraulic hoses and the wiring harness.

4. Operate the attachment and make sure the controls,
switches and lights operate correctly. Check the width of
the attachment as described in CHECK AND ADJUST-
MENTS.

SIDE–SHIFT CYLINDER

Removal (See FIGURE 1.)

1. Disconnect the hydraulic lines at the side–shift cylin-
der. Put caps on the open lines.

2. Connect a lifting device to the cylinder. Remove the
nuts that fasten the cylinder to the carriage and the at-
tachment. Remove the cylinder.

8

Disassembly (See FIGURE 7.)

1. Remove the retainer from the cylinder shell. Remove
the piston and rod from the shell.

2. Remove the nut and piston from the rod. Remove the
packing from the retainer and piston.

Cleaning and Inspection

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety precautions.

Clean the parts of the cylinder with solvent. Inspect the
shell, rod and piston for wear or damage. Install new
parts as necessary.

Assembly (See FIGURE 7.)

1. Install a piston half on the rod. Install the O–ring,
packing assembly and other piston half. Install and
tighten the nut.

2. Install the O–ring and back–up ring on the retainer for
the rod packing. Install the retainer and rod packing on
the rod.

3. Lubricate the shell and packing with clean hydraulic
oil. Install the rod assembly in the shell.

4. Install the wiper in the retainer. Install and tighten the
retainer.

Installation

1. Connect a lifting device to the cylinder. Put the cylin-
der in position and install the pins, spacers and nuts that
fasten the cylinder to the carriage and the attachment.
Tighten the nuts on the pins.

2. Connect the hydraulic lines to the cylinder.

FIGURE 7. SIDE–SHIFT CYLINDER

1. NUT
2. BUSHING
3. WASHER
4. ROD
5. WIPER
6. RETAINER

7. PACKING (ROD)
8. PACKING RETAINER
9. O–RING

10. PISTON HALF

11. PISTON PACKING

12. SHELL

1

2

3

4

5

6

7

8

9

10

11

12

9

10

1

1

9

EXTENSION CYLINDERS

Removal

1. Extend the attachment to the 40 foot position.

2. Remove the nuts that hold the cylinders to the end
beams. Make a note of the location of the washers.

3. Use blocks to support the cylinder rods and complete-
ly retract the cylinders.

4. Disconnect the hoses at the cylinder(s). Put caps on
the open lines.

5. Disconnect the cylinder from the center frame. Re-
move the nut and disc springs at the mount. Make a note
of the number and location of the disc springs.

6. Use a lifting device and carefully remove the cylinder
from the center frame.

Disassembly (See FIGURE 8.)

1. Remove the retainer from the cylinder shell. Remove
the piston and rod from the shell.

2. Remove the nut and piston from the rod. Remove the
packing from the retainer and piston.

Cleaning and Inspection

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety precautions.

Clean the parts of the cylinder with solvent. Inspect the
shell, rod and piston for wear or damage. Install new
parts as necessary.

FIGURE 8. EXTENSION CYLINDER

1. NUT
2. WASHER
3. BUSHING
4. ROD
5. PISTON HALF
6. PISTON PACKING
7. O–RING

8. BACK–UP RING
9. PACKING RETAINER

10. ROD PACKING

11. RETAINER

1

2

3

2

4

5

6

7

8

9

10

11

12

13

14

1

7

5

2

1

12. WIPER
13. SHELL
14. SPRING DISCS

14

2

10

Assembly (See FIGURE 8.)

1. Install a piston half on the rod. Install the O–ring,
packing assembly and other piston half. Install and
tighten the nut.

2. Install the O–ring and back–up ring on the retainer for
the rod packing. Install the retainer and rod packing on
the rod.

3. Lubricate the shell and packing with clean hydraulic
oil. Install the rod assembly in the shell.

4. Install the wiper in the retainer. Install and tighten the
retainer.

Installation

1. Install the extension cylinder in the center frame. See
FIGURE 9. Install the spring discs as follows:

a. Install the flat washer on the rod end of the cylin-

der shell. Install twelve of the spring discs. Install
the discs in groups of three, alternating their di-
rections.

b. Install the rod end in the mount on the center

frame. Install the remaining twelve spring discs.

Install the discs in groups of three, alternating
their directions.

2. Connect the cylinder rod to the outer boom. Make
sure to install the washers in the arrangement noted dur-
ing removal.

3. Operate the extend and retract the attachment several
times before the attachment is used.

FIGURE 9. INSTALL THE EXTENSION

CYLINDER

1. SPRING DISCS (12)
2. CENTER FRAME
3. EXTENSION CYLINDER

1

3

2

1

11

END BEAMS

Removal (See FIGURE 10.)

NOTE: The wear plates for the end beams can be re-
placed or adjusted without removing the end beams.

Disassemble either of the end beam assemblies as fol-
lows:

1. Disconnect the hydraulic lines and electrical cable at
the end beam.

2. Remove the capscrews that hold the block at the bot-
tom of the end beam. The capscrews are inside the end
beam.

3. Connect a lifting device to the end beam. Raise the
end beam until it disengages from the attachment.

Disassembly (See FIGURE 3. and FIGURE 10.)

1. Remove the switches from the locking head.

2. Remove the capscrews, keeper plates and the wear
plates from the top and bottom of the outer boom.

3. Disconnect the hoses from the lock pin cylinder. Re-
move the retainer plate from the locking head. Pull the
pin and cylinder assembly from the from the locking
head.

4. Remove the snap rings from the lock pin. Slide the
bushing off of the lock pin. Drive the retaining pin out of
the cylinder and lock pin.

Cleaning and Inspection

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety precautions.

1. Inspect the wear plates for damage, deep grooves or
cracks. Check the wear surfaces of the end beams.
Install new wear plates as needed. New wear plates must
be installed before their height is at the same level as
their keeper plates.

2. Inspect the lock pins for wear or damage as specified
in CHECKS AND ADJUSTMENTS.

FIGURE 10. END BEAM

1. COVER
2. LOCKING HEAD
3. LOCK PIN
4. RETAINER
5. LOCK CYLINDER
6. END BEAM
7. BLOCK
8. BUTTONS

1

2

3

4

5

6

7

8

Assembly (See FIGURE 3. and FIGURE 10.)

1. Assemble the lock pin and cylinder. Slide the bushing
on the lock pin. Install the retaining rings.

2. Insert the lock pin and cylinder assembly into the
locking head. Install the retainer plate on the locking
head. Connect the hydraulic hoses to the cylinder.

3. Install the switches and adjust as specified in
CHECKS AND ADJUSTMENTS.

12

LOCK PIN CYLINDER

Removal

See End Beams, Disassembly for the procedure to re-
move the lock pin cylinder.

Disassembly

( See FIGURE 11.)

1. Remove the retainer from the cylinder shell. Remove
the piston and rod from the shell.

2. Remove the nut and piston from the rod. Remove the
packing from the retainer and piston.

Cleaning and Inspection

WARNING

Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-

vents, always follow the solvent manufacturer’s rec-
ommended safety precautions.

Clean the parts of the cylinder with solvent. Inspect the
shell, rod and piston for wear or damage. Install new
parts as necessary.

Assembly (See FIGURE 8.)

1. Install a piston half on the rod. Install the O–ring,
packing assembly and other piston half. Install and
tighten the nut.

2. Install the O–ring and back–up ring on the retainer for
the rod packing. Install the retainer and rod packing on
the rod.

3. Lubricate the shell and packing with clean hydraulic
oil. Install the rod assembly in the shell.

4. Install the wiper in the retainer. Install and tighten the
retainer.

FIGURE 11. LOCK PIN CYLINDER

10. RETAINER

11. WIPER

12. SHELL
13. BUSHING
14. WASHER

1. ROD END
2. NUT
3. ROD
4. PISTON HALF
5. O–RING
6. PISTON PACKING
7. BACK–UP RING
8. PACKING RETAINER
9. ROD PACKING

1

2

3

4

5

6

7

8

9

10

11

2

12

13

14

2

4

5

13

FIGURE 12. OPERATOR CONTROLS

1. LOCK PIN SWITCH
2. GREEN LIGHT (LOCKED)
3. AMBER LIGHT (UNLOCKED)
4. ALARM
5. OVERRIDE BUTTON
6. RELAY – EXTEND LOCK PINS
7. RELAY – RETRACT LOCK PINS

1

2

5

6

3

1

7

5

6

7

4

OPERATOR CONTROLS

Repairs (See FIGURE 12. and FIGURE 13. )

Remove the cover from the control box to replace the re-
lays, switches or bulbs.

14

1
2
3
4
5
6
7
8
9

10
11

1
2
3
4
5
6
7
8
9

10
11
12

1
2
3
4
5
6
7
8
9

10
11
12

DH
DZ
DV
DU
EY
EH
DN
BF
EG
EZ
EX

CV

BF

DU

DV

EZ
EG
DN
EH
EX
EY
DH
DZ

EZ
EG
DN
EH
EX
EY
DH
DZ

TO
FRONT
LIGHT
HARNESS

TO SWITCH HARNESS

(TO SHEET 1 of 2)

1

2

3

4

5

6

7

8

9

10

11

12

1. BATTERY POSITIVE
2. LOCK/UNLOCK
3. EXTEND/RETRACT
4. SIDE–SHIFT
5. LOCKED SIGNAL
6. UNLOCKED SIGNAL
7. OVERRIDE
8. WORK LIGHT
9. LOWER HOOK OK (DOUBLE HOOK ONLY)

10. UPPER HOOK OK (DOUBLE HOOK ONLY)

11. GROUND

12. AUXILIARY

15

FIGURE 13. ELECTRICAL SCHEMATIC AND WIRING DIAGRAM (1 OF 2)

AMBER

GREEN

DP

DL

ET

GL
GM
GN

ET
DL
DP

EZ
EG
DN
EH
EX
EY
DH
DZ

GL

GM

GN

ET
DL
DP

DN
EH
EX
EY
DH
DZ

DY
ED

8
7
6
5
4
3
2
1

DY

DQ DS

EC ED

ET

ES

DC EF

EC DQ

DN DJ

I O II

1

7 2

8

3

4

4

4

SWITCH TYPE

EH

EV

EX
EY
EF

DP
DB
DZ
DC
DE
DH
DL
DB
DJ

87

87A

30

86

85

87A

87

30

86

85

TO CHASSIS
HARNESS

TO OPERATOR
COMPARTMENT
HARNESS

AMBER

GREEN

13. AUXILIARY INDICATOR LAMPS
14. ATTACHMENT CONTROL
15. LOCK/UNLOCK SWITCH
16. ALARM
17. OVER RIDE SWITCH
18. LOCK SWITCH RELAY
19. UNLOCK SWITCH RELAY

16

14

15

17

18

19

13

16

1. SWITCH– LOCK PIN LOCKED
2. SWITCH– LOCK PIN UNLOCKED
3. SWITCH– ATTACHMENT SEATED
4. SOLENOID V3 (SIDE–SHIFT)
5. SOLENOID V2

(EXTEND/RETRACT)

6. SOLENOID V1

(LOCK/UNLOCK)

7. BATTERY POSITIVE
8. LOCK/UNLOCK
9. EXTEND/RETRACT

10. SIDE–SHIFT

11. LOCK SIGNAL

12. UNLOCK SIGNAL
13. OVERRIDE
14. WORK LIGHT
15. GROUND
16. EC ATTACHMENT HARNESS
17. RIGHT–HAND ATTACHMENT

LIGHT

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

17

18

1
2
3

4
5
6
7
8
9

11

10

(TO SHEET 2 of 2)

RIGHT

LEFT

CV

BF

FZ

FY

BF

CV

R10

R9

R8

R7

R6

R5

R4

R3

R2

R1

N1

N3

N5

N2

N4

N6

1

2

3

85

86

87

30

85

86

87

30

85

86

87

30

85

86

87

30

85

86

87

30

87A

85

86

87

30

87A

85

86

87

30

85

86

87

30

85

86

87

30

85

86

87

30

 
            

16

19

20

21

21

18. LEFT–HAND ATTACHMENT LIGHT
19. ATTACHMENT LIGHT HARNESS
20. HYDRAULIC MANIFOLD
21. END BEAM

17

FIGURE 14. HYDRAULIC SCHEMATIC (1 OF 2)

FIGURE 15.

1. EXTEND/RETRACT CYLINDERS
2. LOCK PIN CYLINDERS
3. SIDE–SHIFT CYLINDER
4. TO TRUCK (See 2 of 2)
5. SOLENOID VALVE

AY

AX

4

1

1

2

2

3

5

18

5

1. OPERATOR PILOT VALVE – LIFT
2. OPERATOR PILOT VALVE – TILT
3. HYDRAULIC PUMP
4. TO CARRIAGE (See 2 of 2)
5. TILT CYLINDERS
6. MAIN CONTROL VALVES
7. AUXILIARY VALVE
8. TILT VALVE
9. LIFT VALVES

10. LOWERING CONTROL VALVES

11. LIFT CYLINDERS

12. DIRECTION CONTROL VALVE
13. PRESSURE CHECK PORTS

1

2

4

5

6

7

8

9

10

11

12

13

11

5

AY

AX

B

C

D

E

A

F

GA

A

B

GB

K

L

AY

AX

TB

TF

F

4A

4B

3B

3A

HP

A

B

LS
2A

SC

2B

HP

HP

H

B

1B

1A

CG

A

E

9

10

13

#1

#2

#4

5A

5B

19

FIGURE 14. HYDRAULIC SCHEMATIC (2 0F 2)

14. INCHING TREADLE
15. ACCUMULATOR
16. BRAKE TREADLE
17. BRAKES
18. PARK BRAKE
19. THERMOSTATIC BY–PASS VALVE
20. PILOT SUPPLY VALVE
21. STEERING CONTROL UNIT
22. STEERING CYLINDER
23. HYDRAULIC RESERVOIR

14

15

16

17

18

19

20

21

22

23

13

13

13

13

13

13

13

C

G

AC

B1

P1

T1

B1

P1

T1

H

BS

PB

CF

SC

SL

SL

SR SR

CG

P2

P1

P3

#3

#5

#6

#7

#8

#9

#10

3

20

CHECKS AND ADJUSTMENTS

CHECK AND ADJUST THE END BEAM
SWITCHES (See FIGURE 16.)

1. Check the operation of the switches by operating the
lock pin switch on the control console. If the lights on
the console operate as described the switches on the end
beams do not need adjustment.

2. The position of the switches for the lock pins can be
changed by moving the switch with the adjustment nuts.
The correct clearance between the switch and the mov-
ing part is 3.0 to 4.0 mm (0.12 to 0.16 in).

FIGURE 16. SWITCH ADJUSTMENTS

1. ADJUSTMENT NUT
2. SWITCH
3. MOVING PART

3.0 to 4.0 mm
(0.12 to 0.16 in)

1

1

2

3

1

1

CHECK THE LOCK PINS

WARNING

Do not use the attachment if any of the lock pins are
worn or damaged.

Check the lock pins for wear or damage as follows:

a. Every 250 hours: Inspect the lock pins for cracks,

bending, wear or surface damage. Measure the
diameter of the lock pin. Replace the lock pin if
its diameter is reduced by 10%.

b. Every 2000 hours: Remove the lock pins from the

end beams. Check the lock pins for cracks with a
dye penetrant or magnetic particle inspection.
Replace a worn or damaged lock pin.

LIFT CHAIN ADJUSTMENTS
(See FIGURE 10.)

When correctly adjusted:

•

The tension will be the same on each chain of the
chain set. Check tension by pushing on both
chains at the same time.

•

The chains must travel freely through the com-
plete cycle.

1. Put the lift truck on a flat, level surface. Put the mast in
a vertical position. Lower the carriage completely. Ad-
just the lift chains so that the lowest part of the attach-
ment end beams are 25 mm (1.0 in) above the surface
(floor). If the adjustment is not correct, adjust the chain
anchors. Make sure each anchor is adjusted the same
amount.

2. Check the clearance of the carriage when the mast is
fully extended. The carriage stops must not touch the
stop on the top crossmember of the inner mast. The
chains are too tight if the carriage touches the
crossmember. If the chains are too tight adjust the chain
anchors. Make sure each anchor is adjusted the same
amount.

NOTE: When the chain adjustments are complete,
make sure that the threads on the nuts of the chain an-
chors are completely engaged. Make sure that the lock-
nuts on the chain anchors are drawn up tight against the
keeper.

CARRIAGE ADJUSTMENTS
(See FIGURE 10.)

1. Find the tightest fit between the wear plates and the
channels of the inner mast.

2. The maximum clearance between the wear plate and
the inner channel is 0.5 to 1.3 mm (0.020 to 0.050 in) at
the point of the tightest fit. When installing the wear
plates, be sure to lubricate the face of the block with
multi–purpose grease.

3. Adjust the shim arrangement for each wear plate. If
necessary, a maximum of five shims can be added be-
tween the wear plate and the bracket. If more than five
shims are required, install a new wear plate. Also check
the distance that the wear plate extends from the bracket.

21

The maximum distance that the wear plate can extend
from the bracket is 6.0 mm (0.24 in). Tighten the cap-
screws for the wear plates to 9 N.m (80 lbf in) maxi-
mum.

4. Keep the shim arrangement on each side of the car-
riage approximately equal. The carriage must be paral-
lel with the inner channel within + 1.5 mm (0.060 in).

5. After adjustment, lubricate the surface of the channels
that touch the wear plates with a thin layer of grease. Do
not lubricate the surfaces for the load rollers.

CHECK AND ADJUST THE WIDTH OF
THE ATTACHMENT

1. See FIGURE 4. and make sure all of the wear plates
are in position and adjusted correctly. Add shims as nec-
essary to the wear plates at the ends of the center frame.

2. Extend the attachment to the 12.2 m (40 foot) posi-
tion. Measure the distance between the centers of the
lock pins. The correct distance is 11.984 m (39 feet, 3.84
inches). This distance can be changed by moving the
mounts for the extension cylinders. The mounts on the
center frame have slots for adjustment.

22

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Attachment does not extend
or retract, or does not
operate smoothly.

Extension cylinders do not operate
correctly.
Wear plates are damaged, missing or
not adjusted correctly.

Wear plates are causing a restriction
within the boom(s).

Repair extension cylinders.

Repair and adjust wear plates.

Install new wear plates.

ELECTRICAL SYSTEM

Amber lights (lock pins
unlocked) stay on.

Proximity switch(es) at end beam are
damaged or not adjusted correctly.

Bulb(s) are damaged. Wires are
disconnected.

Relay 3 or 4 does not operate
correctly.

Adjust or install new switches.

Install new bulbs. Connect wires.

Install a new relay 3 or 4.

Green lights (lock pins
locked) stay on.

Proximity switch(es) at end beam are
damaged or not adjusted correctly.

Bulb(s) are damaged. Wires are
disconnected.

Relay 1 or relay 2 does not operate
correctly.

Adjust or Install a new switch.

Install a new bulb.

Install a new relay 1 or 2.

Lock pins do not retract or
extend with override switch.

Wiring harness is damaged or
disconnected.

Override switch is damaged.

Lock/unlock switch is damaged.

Relay 10 is damaged.

Solenoid valve is damaged.

Repair or connect harness.

Replace override switch.

Replace lock/unlock switch.

Replace relay 10.

Replace solenoid valve.

Lock pins do not extend or
retract.

Wiring harness is damaged or
disconnected.

Lock/unlock is switch damaged.

Relay 5, 6, or 7 is damaged.

Solenoid valve is damaged

Repair or connect harness.

Replace lock/unlock switch.

Replace relay 5, 6, or 7.

Replace solenoid valve

Attachment does not
side–shift

Wiring harness is damaged or
disconnected.

Side–shift switch is damaged.

Repair or connect harness.

Replace side–shift switch.

Attachment does not extend
or retract

Wiring harness is damaged or
disconnected.

Extend/retract switch is damaged.

Lock pin circuit is faulty.

Attachment seated circuit is faulty.

Repair or connect harness.

Replace extend/retract switch.

Replace or adjust proximity switches
(locked) on end beam.
Check relays 3, 4, 9 and replace if
damaged.

Replace or adjust proximity switches
(seated) on end beam.
Check relays 5, 6, 8, 9 and replace if
damaged.

23

HYDRAULIC SYSTEM

Hydraulic functions do not
operate.

No oil flow to the attachment
cylinders.

Relief valve(s) not adjusted correctly.

Hydraulic lines are not connected, are
damaged or have a restriction.

Cylinder(s) has damaged internal
parts.

Check hydraulic pump for output.

Adjust relief valve(s).

Connect, repair or install new
hydraulic lines.

Repair or install a new cylinder.